TWI701376B - Formwork for concrete forming, concrete forming body formed by the concrete forming body, concrete structure using concrete forming body, method of manufacturing concrete forming body, and method of manufacturing concrete structure - Google Patents

Abstract

The invention provides a formwork for concrete forming which can be used repeatedly. The template (10) for forming concrete includes: a base material (1); and a protective layer (2) provided on at least a part of the surface of the base material (1); and the protective layer (2) includes flaky stainless steel particles (21) .

Description

Formwork for concrete forming, concrete forming body formed by the same, concrete structure using concrete forming body, method for manufacturing concrete forming body, and method for manufacturing concrete structure

The present invention relates to a formwork for forming concrete, a concrete forming body formed by the concrete forming body, a concrete structure using the concrete forming body, a method for manufacturing a concrete forming body, and a method for manufacturing a concrete structure.

The concrete before curing (hereinafter, also referred to as "ready-mixed concrete") is a fluid mixture made of aggregates such as gravel or gravel, cement, and water. The ready-mixed concrete forming system is produced by putting ready-mixed concrete into a form for concrete forming (hereinafter also referred to as "formwork"), applying vibration to the put-in ready-mixed concrete to compact it, and then making the ready-mixed concrete The concrete is cured.

As the material of the template, wood, paper, metal, resin, etc. are generally known. Examples of metals include iron (for example, carbon steel, etc.), stainless steel, aluminum, and aluminum alloys. Among them, aluminum and aluminum alloys are excellent in light weight and relatively high strength.

However, when the aluminum formwork is not treated on its surface, the aluminum reacts with the alkali components in the concrete, so that the surface of the obtained concrete will not become smooth and damage the appearance of the finishing. Therefore, the surface of the template made of aluminum is usually applied with a coating film as a protective layer or subjected to a protective treatment.

For example, in Japanese Patent Laid-Open No. 2002-327532 (Patent Document 1), it is disclosed that the surface is treated with an alumina film, and then a coating film containing acrylic resin is applied. Aluminum template. In addition, Japanese Patent Laid-Open No. 07-195342 (Patent Document 2) discloses a template made of aluminum alloy coated with a surface coating layer having an innermost layer and an outermost layer, and the innermost layer It comprises a resin layer containing a (meth)acrylic polymer, and the outermost layer comprises a resin layer containing a fluorine-(meth)acrylic copolymer.

[Prior Technical Literature] [Patent Literature]

[Patent Document 1] Japanese Patent Laid-Open No. 2002-327532

[Patent Document 2] Japanese Patent Laid-Open No. 07-195342

However, as disclosed in Patent Literature 1 and Patent Literature 2, the hardness of the coating film formed on the surface of the former template is not high. Therefore, there are many cases in which the ready-mixed concrete is poured into the concrete forming template. The impact caused by the impact of the bone material on the surface of the template or the contact with the vibrator used to achieve vibration causes the coating film on the surface of the template to be damaged. In addition, during demolding, there are also situations where impact injuries or scratches occur during field operations. Moreover, as for the result of damage, the part of the coating film with impact damage becomes the state where aluminum is exposed, so aluminum reacts with the alkali component in the concrete, so that the surface state of the obtained concrete will not become smooth and damage the fine The appearance of processing.

Furthermore, there is a tendency that the concrete and the formwork are in close contact, so that it takes time to separate (release) the concrete and the formwork, or the concrete adheres to a part of the formwork. Therefore, it is impossible to obtain a concrete formed body of the desired shape, and there is a problem that the formwork cannot be repeatedly used.

The present invention was completed in view of the above-mentioned status quo, and its object is to provide a reusable concrete forming formwork, a concrete forming body formed by the same, a concrete structure using the concrete forming body, and a method for manufacturing the concrete forming body And the manufacturing method of concrete structure.

The concrete forming template of the present invention includes: a substrate; and a protective layer provided on at least a part of the surface of the substrate; and the protective layer includes flaky stainless steel particles.

In the above-mentioned concrete forming form, it is preferable that the base material contains at least any one of aluminum or an aluminum alloy.

In the above-mentioned concrete forming form, it is preferable that the protective layer contains flaky stainless steel particles of 5 mass% or more and 58 mass% or less.

In the above-mentioned concrete forming formwork, it is preferable that the pass rate of the sieve of 150 μm mesh of flaky stainless steel particles is 99.0% by weight or more.

The present invention also relates to a concrete formed body formed by the above-mentioned concrete forming template and a concrete structure provided with the concrete formed body.

The manufacturing method of the concrete forming body of the present invention includes the steps of: arranging one or more concrete forming templates into a desired positional relationship, filling the concrete forming templates with ready-mixed concrete; and mixing the ready-mixed concrete The step of separating the concrete formed body formed by the curing of concrete from the formwork for concrete forming.

The manufacturing method of the concrete structure of this invention has the following steps: The step of manufacturing a concrete structure using the concrete formed body manufactured by the manufacturing method of the said concrete formed body.

According to the formwork for concrete forming of the present invention, the effect of being able to be used repeatedly is exerted.

1‧‧‧Substrate

1a‧‧‧surface

1b‧‧‧surface

2‧‧‧Protection layer

3‧‧‧The first middle layer

4‧‧‧Second middle layer

10‧‧‧Formwork for concrete forming

21‧‧‧Flake stainless steel particles

22‧‧‧Resin

II‧‧‧Region

Fig. 1 is a schematic cross-sectional view of the concrete forming formwork of the embodiment.

Fig. 2 is an enlarged schematic diagram showing area II of Fig. 1.

[Formwork for forming concrete and its manufacturing method]

<Composition of Formwork for Concrete Forming>

Fig. 1 shows a schematic cross-sectional view of a concrete forming form (hereinafter, also referred to as "form") of this embodiment. As shown in FIG. 1, the template 10 of this embodiment includes a substrate 1 and a protective layer 2 provided on a surface 1 a of the substrate 1.

Moreover, as shown in FIG. 1, the template 10 may also have any other layer between the base material 1 and the protective layer 2. The other layers in this embodiment include the first intermediate layer 3 provided on the surface 1 a side of the base material 1 and the second intermediate layer 4 provided between the first intermediate layer 3 and the protective layer 2.

The shape of the form 10 is not particularly limited, as long as it is a shape that can form a space for forming the required concrete formed body. For example, when the purpose is to manufacture a cylindrical concrete formed body, the form 10 may be a cylindrical shape, or a plate-shaped member in a circular arc, and a cylinder can be formed by a combination of a plurality of plate-shaped members The shape of the shape.

(Substrate)

The material of the substrate 1 is not particularly limited, and wood, paper, metal, resin (synthetic resin and natural resin), and these composite materials can be used. Examples of the metal include iron (for example, carbon steel), stainless steel, magnesium, magnesium alloy, aluminum, and aluminum alloy. Among them, aluminum or an aluminum alloy is preferable in terms of light weight, excellent workability, relatively high strength, and low cost. The aluminum alloy is not particularly limited as long as it contains aluminum as the main metal. For example, alloys containing aluminum and at least one selected from silicon, magnesium, and transition metals can be cited. In this embodiment, a case where the material of the base material 1 is aluminum will be described.

The shape of the substrate 1 is approximately the same as the shape of the template 10. In addition, the thickness of the substrate 1 is not particularly limited, but is preferably 0.1 mm or more and 50 mm or less, and more preferably 1 mm or more and 5 mm or less. In this case, the template 10 can have sufficient strength, and can also maintain light weight and low cost.

(The protective layer)

The protective layer 2 is provided on at least a part of the surface of the substrate 1. For example, the protective layer 2 can be provided on the surface 1a, on the surface 1b on the opposite side of the surface 1a, and on both surfaces of the surfaces 1a and 1b, as long as it is provided on the surface at least on the side in contact with the concrete. In this embodiment, the protective layer 2 is a layer provided on the outermost surface of the surface 1a of the base material 1 and in contact with concrete.

As shown in FIG. 2, the protective layer 2 includes flaky stainless steel particles 21. Specifically, the protective layer 2 is a layer in which the flaky stainless steel particles 21 are dispersed in the resin 22, and may contain additives as optional components.

The protective layer 2 preferably contains flaky stainless steel particles 21 of 5 mass% or more and 58 mass% or less. When the content of the flaky stainless steel particles 21 in the protective layer 2 is more than 5% by mass, the protective layer 2 may have higher hardness. Thereby, when the impact caused by the impact of the bone material on the surface of the template 10 or the impact caused by the contact with the vibrator used to realize the vibration, the damage of the protective layer 2 can be suppressed, and the substrate can be suppressed. The reaction between material 1 and the alkali components in concrete. In addition, in the protective layer 2, the flaky stainless steel particles can be aligned in layers (see FIG. 2 ), so that the components (permeable components such as alkali components) in the concrete can be effectively prevented from penetrating in the thickness direction of the protective layer 2. Thereby, the damage and deterioration of the protective layer caused by the penetration of the penetrating component, or the corrosion of the substrate 1 caused by the contact between the penetrating component and the substrate 1 can be suppressed.

On the other hand, when the content of the flaky stainless steel particles 21 in the protective layer 2 exceeds 58% by mass, the content of the resin 22 is relatively decreased, thereby the frequency of occurrence of cracks in the protective layer 2 tends to increase. If a crack occurs in the protective layer 2, the hardness of the protective layer 2 may decrease and the damage of the protective layer may extend from the cracked part, or the protective layer 2 may peel off depending on the situation. In this case, there is a possibility that the reaction between the base material 1 and the alkali component in the concrete cannot be suppressed, and the surface shape of the obtained concrete formed body may not become smooth. The content of the flaky stainless steel particles 21 in the protective layer 2 is more preferably 23% by mass or more and 55% by mass or less.

The protective layer 2 preferably contains 42% by mass or more and 95% by mass or less of the resin 22. When the content of the resin 22 in the protective layer 2 is 42% by mass or more, the generation of cracks in the protective layer 2 can be suppressed. When the content of resin 22 in the protective layer 2 exceeds 95% by mass At this time, the content of the flaky stainless steel particles 21 is relatively decreased, whereby the hardness of the protective layer 2 or the effect of suppressing the penetration of the components of the concrete tends to decrease. The content of the resin 22 in the protective layer 2 is more preferably 50% by mass or more and 70% by mass or less.

The thickness of the protective layer 2 is not particularly limited. For example, it can be 10 μm or more and 100 μm or less. In this case, the flaky stainless steel particles 21 can be arranged in a layered manner along the thickness direction of the protective layer 2, so that the protective layer 2 can have higher hardness and can effectively prevent the penetration Soaking of ingredients. In contrast, when the thickness of the protective layer 2 is less than 10 μm, the hardness of the protective layer 2 tends to become insufficient. When the thickness exceeds 100 μm, the workability when forming the protective layer 2 decreases or the cost Increasing tendency.

The composition of the flaky stainless steel particles 21 contained in the protective layer 2 is not particularly limited, and examples thereof include well-known stainless steels such as ferrite stainless steel, austenitic stainless steel, Matian stainless steel, and duplex stainless steel.

In particular, it is preferable to use ferrite stainless steel or austenitic stainless steel in terms of high corrosion resistance and workability. Among ferrite stainless steels, SUS (Steel Use Stainless, Japanese Stainless Steel Standard) 430, NSS445M2 and NSS447M1 manufactured by Nisshin Steel Co., Ltd. are preferred. Among austenitic stainless steels, SUS304, SUS316, and SUS316L are preferred. . In addition, in terms of high corrosion resistance under extremely severe corrosive environments, NSSURC manufactured by Nisshin Steel Co., Ltd. can also be preferably used.

Furthermore, the flaky stainless steel particles 21 may also contain inevitable impurities other than stainless steel. However, from the viewpoint of corrosion resistance and workability, it is preferable that the content ratio of the inevitable impurities in the flaky stainless steel particles 21 be 1% by mass or less.

In addition, it is preferable that the flaky stainless steel particles 21 have a 150 μm mesh with a pass rate of 99.0% by mass or more. That is, the flaky stainless steel particles 21 of this embodiment are an aggregate of particles having a flaky shape, and it is preferable that 99.0% by mass or more of the aggregate pass through the mesh 150μm mesh.

In this manual, the "pass rate" of the screen is defined as the mass of the flaky stainless steel particles before sieving with the wet screen as S1, and the flaky stainless steel particles remaining on the screen after the sieving When the mass is S2, it can be obtained based on the following formula (1).

Pass rate (mass%)={(S1-S2)/S1}×100 (1).

When the flaky stainless steel particles 21 have a pass rate of 99.0% by mass or more with respect to a 150μm mesh, in the protective layer 2, the flaky stainless steel particles 21 are easy to be arranged in parallel along the thickness direction of the protective layer 2. Therefore, the surface of the protective layer 2 can have higher smoothness. If the smoothness of the surface of the protective layer 2 is high, the surface of the obtained concrete formed body is likely to become smooth, and furthermore, the separation of the formwork 10 and the concrete formed body is also likely to be easier.

On the other hand, when the pass rate of the 150μm mesh is less than 99.0% by mass, the flaky stainless steel particles 21 protrude from the surface of the protective layer 2, so the smoothness of the surface of the protective layer 2 becomes low. Or, it becomes easy to generate voids in the protective layer 2. If the flaky stainless steel particles 21 protrude from the surface of the protective layer 2, cracks are likely to occur from this part, and if a cavity is generated in the protective layer 2, the protective layer 2 becomes easy to peel from the cavity. The pass rate of the flaky stainless steel particles 21 to a sieve with a mesh of 150 μm is more preferably 99.9% or more.

In addition, the flaky stainless steel particles 21 preferably have a diameter (D ₉₀ ) of 90% of the cumulative volume particle size distribution of 70 μm or less, more preferably 55 μm or less, and still more preferably 52 μm or less. In this case, the protective layer 2 with fewer defects can also be formed, so the template 10 provided with the protective layer 2 can have higher hardness and higher corrosion resistance, can exhibit good mold release and can be used repeatedly The excellent effect.

In addition, for the same reason, the diameter (D ₅₀ ) of 50% of the volume cumulative particle size distribution of the flaky stainless steel particles 21 is preferably 1 μm or more and 100 μm or less, more preferably 3 μm or more and 50 μm or less, more preferably 5 μm or more and 50 μm or less, particularly preferably 8 μm or more and 29 μm or less.

In this specification, "volume cumulative particle size distribution" refers to the volume cumulative particle size distribution obtained by measuring the volume average particle size of flaky stainless steel particles. For example, the so-called "50% diameter is 1μm or more and 100μm or less" refers to the cumulative frequency (%) on the vertical axis and the particle size (μm) on the horizontal axis of the volume cumulative particle size distribution curve, the cumulative degree of 50% of the particle size It is 1 μm or more and 100 μm or less. Similarly, the so-called "90% diameter is 70μm or less" means that in the volume cumulative particle size distribution curve with cumulative frequency (%) on the vertical axis and particle size (μm) on the horizontal axis, the particle size with a cumulative degree of 90% is 70μm the following. Furthermore, the above-mentioned volume average particle diameter can be obtained by calculating the volume average based on the particle size distribution measured by the laser diffraction method.

In addition, the flaky stainless steel particles preferably have an average thickness (t) of 0.01 μm or more and 1.0 μm or less, and an average particle diameter (D ₅₀ ) of 1 μm or more and 100 μm or less. More preferably, the average thickness (t) is 0.03 μm or more and 0.5 μm or less, the average particle size (D ₅₀ ) is 3 μm or more and 50 μm or less, and t is more preferably 0.03 μm or more and 0.33 μm or less, and D ₅₀ is 5 μm. More than and 50 μm or less, more preferably t is 0.16 μm or more and 0.33 μm or less, and D ₅₀ is 8 μm or more and 29 μm or less. In this case, flaky stainless steel particles are preferably laminated in the thinner protective layer 2, for example, in the protective layer 2 with a thickness of 10 μm or less. Therefore, the resistance to corrosive substances such as alkali components (permeable components) can be improved. Labyrinth effect (blocking effect).

In addition, the hardness of the flaky stainless steel particles tends to increase due to the fact that the thickness of the flaky stainless steel particles with a larger average particle size (D ₅₀ ) is relatively larger, and the hardness of each flaky stainless steel particle becomes higher. Therefore, the template 10 provided with the protective layer 2 containing the flaky stainless steel particles satisfying the various ranges of the above-mentioned characteristics can have higher hardness and higher corrosion resistance, and can exhibit excellent mold release properties and repeated use. effect.

On the other hand, when the average thickness (t) is less than 0.01 μm, the processing becomes difficult in the manufacturing steps, etc., and when (t) exceeds 1.0 μm, the protective layer 2 is required to achieve a better build-up. Thicken. The same problem occurs when D _{50 is} less than 1 μm and when it exceeds 100 μm.

In this specification, the average thickness (t) of the flaky stainless steel particles is calculated by the water surface diffusion area method (cm ² /g) in accordance with JIS (Japanese Industrial Standards) K5906: 1998.

In addition, in the flaky stainless steel particles 21, the ratio of the average particle diameter (D ₅₀ ) to the average thickness (t), that is, the average aspect ratio (D ₅₀ /t), is preferably 5 or more and 500 or less, more preferably 10 or more And below 100.

When the average aspect ratio is less than 5, it tends to be difficult to fully exhibit the effect of suppressing the penetration of the penetrating component in the concrete. When the average aspect ratio exceeds 500, there is a tendency that the viscosity of the paint used to form the protective layer 2 is greatly increased and it becomes difficult to ensure an appropriate amount of the paint. Moreover, when the average aspect ratio exceeds 500, the loose specific gravity of the flaky stainless steel particles 21 is small, so the gaps between the flaky stainless steel particles 21 existing in the protective layer 2 increase, and as a result, the corrosion resistance of the protective layer 2 decreases. tendency. Furthermore, there is a tendency that the hardness of the protective layer 2 also decreases due to this.

The resin 22 contained in the protective layer 2 is not particularly limited, and examples include epoxy resin, polyester resin, alkyd resin, acrylic resin, acrylic polysiloxane resin, vinyl resin, silicone resin, and polyamide resin. , Polyamide imide resin, fluororesin, synthetic resin latex, skilled oil, chlorinated rubber, natural resin, amino resin, phenol resin, polyisocyanate resin, urea resin, etc. Moreover, these resins can also be combined suitably.

Examples of additives optionally included in the protective layer 2 include dispersants, defoamers, anti-precipitation agents, hardening catalysts, and lubricants. In particular, when it is desired to further improve the peelability between the protective layer 2 and the concrete molded body, it is preferable to use polytetrafluoroethylene, ethylene-tetrafluoroethylene copolymer, polychlorotrifluoroethylene, polyvinyl fluoride, polyvinylidene Vinyl fluoride, hexafluoropropylene-perfluoro(alkyl vinyl ether) copolymer, fluorine resin such as vinyl fluoride polypropylene copolymer, fluorine monomer such as tetrafluoroethylene, silicone oil, molybdenum disulfide, disulfide Tungsten, boron nitride, graphite, etc. are used as lubricants. The slip agent can be contained in a layer different from the protective layer 2. In this case, different layers can also be formed on the surface of the protective layer 2 (the outermost surface in contact with the concrete).

(Other layers)

The first intermediate layer 3 is a compound coating film. By providing a compound coating on the surface 1a of the base material 1, the adhesion to the protective layer 2 formed thereon can be improved. In addition, when the protective layer 2 is assumed to be damaged, the aluminum and alkali components can be suppressed. reaction. Furthermore, the aluminum compound film is a chromate film.

The second intermediate layer 4 is a coating film formed of a well-known paint as a primer, intermediate paint, gap filler, initial paint, colored paint, etc. A second intermediate layer 4 is provided between the base material 1 and the protective layer 2 so as to correct the irregularities on the surface of the base material 1 or improve the adhesion of the template 10.

In this embodiment, the template 10 is provided with a first intermediate layer 3 as a compound coating between the base material 1 and the protective layer 2, and a second intermediate layer as a coating formed by the previous coating The case of 4 is illustrated, but the configuration of the template 10 is not limited to this. For example, it may not have other layers, may have only the first intermediate layer 3 or only the second intermediate layer 4 as other layers, or may further include other layers.

<Manufacturing method of formwork for concrete forming>

The template 10 of this embodiment can be manufactured by the following method: for example, a first intermediate layer 3, a second intermediate layer 4, and a protective layer 2 are sequentially formed on the surface of a substrate 1 made of aluminum. The shape and size of the base material 1 are appropriately set according to the shape and size of the target concrete formed body.

The first intermediate layer 3 as a compound coating can be formed by a known method such as chromic acid coating treatment and phosphoric acid-chromic acid coating treatment.

The second intermediate layer 4 can be formed by a well-known coating method using a well-known undercoating agent, middle coating agent, caulking agent, primer, and coloring agent.

The protective layer 2 can be formed using a paint containing at least flaky stainless steel particles and resin to make. As the paint, there are solvent-based paints that contain a solvent in the ingredients, and powder paints that do not contain a solvent, but in terms of ease of handling, solvent-based paints are preferred.

In the case of using a solvent-based paint, the paint is applied to the second intermediate layer 4, while evaporating the solvent in the paint, and curing the resin, thereby forming the protective layer 2. The coating method of the protective layer 2 is not particularly limited. In addition to the well-known coating (coating) method, such as spray, brush, roller, dipping, etc., a printing method (inkjet printing) can be used. , Screen printing, gravure printing), dripping method, etc.

The flaky stainless steel particles in the protective layer 2 of the flaky stainless steel particles contained in the paint can be produced, for example, by the following method.

First, stainless steel particles (first particles) are produced using a well-known atomization method, crushing method, rotating disk method, rotating electrode method, cavitation etching method, melt spinning method, and the like. From the viewpoint of manufacturing cost and uniformity, it is preferable to use an atomization method.

Next, the prepared stainless steel particles (first particles) are pulverized by a wet ball mill, dry ball mill, bead mill, etc., to produce flattened stainless steel particles (second particles). From the viewpoint of safety and workability, it is preferable to use a wet ball mill. In particular, by using a steel ball with a diameter of 1/4 inch or less, it can be efficiently flattened to the target size. Furthermore, the grinding time is preferably 1 hour or more and 48 hours or less, more preferably 3 hours or more and 10 hours or less.

The obtained stainless steel particles (second particles) can also be used as flake-shaped stainless steel particles, but it is preferable to use a 150μm mesh sieve for sieving, and use the stainless steel particles (third particles) that have passed through the screen as flakes Shaped stainless steel particles. The third particles are flaky stainless steel particles with a 150μm mesh with a pass rate of 99.0% by mass or more.

In addition, in the above-mentioned sieving step, a sieve containing stainless steel with a diameter of 200 mm or more and 2000 mm or less can also be used. In this case, the abrasion or damage of the screen is less, and the screening can be performed efficiently. In addition, when the stainless steel particles that have undergone the deformation step are in a slurry state, it is preferable to wash the slurry with a solvent such as mineral spirits, and then Line screening step. The mesh size of the used mesh is less than 150μm.

In the foregoing, the D _{90 of the} stainless steel particles (first particles) is preferably 5 μm or more and 50 μm or less, more preferably 40 μm or less. In this case, the recovery rate of stainless steel particles (third particles) obtained after sieving can be improved. On the other hand, when D ₉₀ exceeds 50 μm, the recovery rate of stainless steel particles (third particles) obtained after sieving may decrease, or the sieving step may take a long time. In addition, when the stainless steel particles (first particles) D _{90 is} less than 5 μm, the raw material cost becomes high.

In addition, the D ₅₀ of the stainless steel particles (first particles) produced is preferably 2 μm or more and 20 μm or less. In this case, the recovery rate of stainless steel particles (third particles) can also be increased in the same manner as described above. Furthermore, the so-called recovery rate refers to the ratio of the mass of the finally obtained stainless steel particles (third particles) to the mass of the stainless steel particles (first particles) used. In addition, since the meaning of D ₉₀ and D ₅₀ of stainless steel particles and the calculation method are the same as those of D ₉₀ and D _{50 of} flaky stainless steel particles, the description will not be repeated.

According to the manufacturing method detailed above, the flaky stainless steel particles used in the present invention can be manufactured. Furthermore, the manufacturing method of the flaky stainless steel particles used in the present invention is not limited to the above steps, and may include other steps.

The resin contained in the paint for forming the protective layer 2 can be appropriately selected from the above-mentioned resins.

When a solvent-based paint is used to form the protective layer 2, the solvent contained in the paint can be selected from organic solvents such as alcohols, glycols, ketones, esters, ethers, and hydrocarbons, water, etc. Choose appropriately. Furthermore, the compounding amount of the solvent in the paint is preferably 20 parts by mass or more and 80 parts by mass or less with respect to 100 parts by mass of the resin. If the solvent is less than 20 parts by mass, the dispersibility of the flaky stainless steel particles in the coating becomes insufficient, and if it is more than 80 parts by mass, environmental pollution due to evaporation of the solvent becomes a problem.

<Effects>

The hardness of the previous protective layer system described in Patent Document 1 and Patent Document 2 is insufficient High enough. Therefore, when the ready-mixed concrete is poured into the formwork, the protective layer is damaged due to the impact of the aggregate on the surface of the formwork, or when vibration is applied, the protective layer is damaged due to the impact of the aggregate on the surface of the formwork. In addition, during demolding, there are also situations where impact injuries or scratches occur during field operations. If the protective layer is damaged, the concrete formed body with the desired appearance (smooth surface) cannot be obtained, and the formwork cannot be repeatedly used.

In contrast, the protective layer 2 provided in the template 10 of the present embodiment includes flaky stainless steel particles 21, and therefore has a higher hardness than the previous protective layer. Therefore, the damage of the protective layer as described above can be suppressed, so a concrete formed body of a desired shape can be manufactured, and the form 10 can be used repeatedly.

In addition, the previous protective layer containing resin has a low hardness, so it is easy to produce fine cracks that will not affect the shape of the concrete formed body. If there are fine cracks in the protective layer, it will be supplemented by the lower hardness, and the alkali components in the concrete will also penetrate into the protective layer from the cracks, so the fine cracks in the protective layer will develop into larger ones. The danger of injury. In particular, when the substrate is aluminum or aluminum alloy, there are cases where the alkali component reacts with aluminum to corrode the surface of the substrate, and the protective layer itself peels off from the substrate, making it difficult to continue to be used as a template.

In contrast, in the present embodiment, the flaky stainless steel particles aligned to the protective layer 2 can suppress the penetration of alkali components, and therefore can have high corrosion resistance, thereby suppressing the above-mentioned problems. . In particular, when the flaky stainless steel particles 21 have a pass rate of 99.0% by mass or more with respect to the 150μm mesh, the flaky stainless steel particles can be arranged better, so the above-mentioned problems can be further effectively suppressed The production. In addition, when D ₉₀ of the flaky stainless steel particles 21 is 70 μm or less, when D ₅₀ is 1 μm or more and 100 μm or less, or when the average thickness (t) is 0.01 μm or more and 1.00 μm or less, It can be said to be the same.

In addition, in this embodiment, the template 10 includes a first intermediate layer 3 and a second intermediate layer 4 between the base material 1 and the protective layer 2. In this way, when it is assumed that the protective layer 2 has been damaged, it can also be Inhibit the contact between the alkali component and other corrosive components in the concrete and the base material 1. In addition, by having such other layers, the adhesion between the entire layers of the template 10 can be improved.

[Concrete forming body and its manufacturing method]

The concrete forming system of the present embodiment is formed by using the above-mentioned concrete forming template, for example, concrete pillars and walls. The concrete formed body can be produced in the following manner.

First, the above-mentioned concrete forming formwork is arranged in a desired positional relationship. At this time, the space formed by the formwork for concrete forming is set so as to match the shape of the target concrete forming body.

As a template for concrete forming to be arranged, one may be used, or two or more may be appropriately combined and used. Furthermore, when the shape of the concrete forming body is complicated, for example, when a joint groove is to be provided in the concrete forming body, the joint rod can also be arranged on the concrete forming template.

Next, fill ready-mixed concrete into the placed concrete forming formwork. Vibration is applied to the filled ready-mixed concrete for compaction. After vibration, the ready-mixed concrete is allowed to solidify. Thereby, the concrete formed body is formed in the formwork for concrete forming. It is also possible to apply a release agent on the surface of the protective layer 2 before filling the ready-mixed concrete.

Secondly, the formwork for concrete forming is separated from the concrete forming body. For example, the two can be separated by peeling off the concrete forming formwork from the concrete forming body.

Based on the above, the above-mentioned template for concrete forming can be used to produce a concrete formed body.

The concrete forming system of this embodiment is produced using the above-mentioned template for concrete forming. The above-mentioned concrete forming form includes a protective layer with higher hardness and higher corrosion resistance, so that the surface damage caused by the concrete being poured or vibration is suppressed. Therefore, the surface of the produced concrete formed body becomes smooth, and the appearance can be improved.

[Concrete structure and its manufacturing method]

The concrete structure system of this embodiment is provided with a shaped concrete body. That is, the concrete structure only needs to be provided with a concrete formed body, and may be provided with other members. In addition to using the formwork for concrete forming of this embodiment, a concrete structure may be produced by a previously known method.

The concrete structure of the present embodiment is provided with a concrete formed body produced using the above-mentioned concrete forming template, so the surface thereof is smoothed, so that the appearance can be excellent.

[Example]

Hereinafter, the present invention will be described in more detail by enumerating examples, but the present invention is not limited to these examples.

<Production of flake stainless steel particles>

(Flake stainless steel particles 1)

A spherical stainless steel powder (first particle) having D ₅₀ of 17 μm and D ₉₀ of 37 μm was prepared. The stainless steel particles (first particles) were put into a ball mill in which 1/4-inch steel balls were placed and flattened to produce flake-shaped stainless steel particles (second particles). Next, the flaky stainless steel particles (second particles) were sieved using a sieve with a mesh of 38 μm. The flaky stainless steel particles (third particles) in the paste form that passed through the mesh were designated as flaky stainless steel particles 1.

(Flake stainless steel particles 2)

A sieve with a mesh of 150 μm is used instead of a sieve with a mesh of 38 μm, except that the paste-like flaky stainless steel particles 2 are produced by the same method as the flaky stainless steel particles 1.

(Flake stainless steel particles 3)

Use spherical stainless steel powder (first particle) with D ₅₀ of 3 μm and D ₉₀ of 5 μm instead of spherical stainless steel powder (first particle) with D ₅₀ of 17 μm and D ₉₀ of 37 μm. Otherwise, borrow The paste-like flaky stainless steel particles 3 are produced by the same method as the flaky stainless steel particles 1.

<Evaluation of flake stainless steel particles>

Measure the solid content (mass %), D ₅₀ and D ₉₀ of the obtained paste-like flaky stainless steel particles 1 to 3, and then use a 150μm mesh to screen the flaky stainless steel particles 1 to 3. Calculate the passing rate of each particle. The solid content, D ₅₀ and D ₉₀ , and pass rate are calculated by the following methods, respectively. The results are shown in Table 1. Furthermore, in Table 1, D ₅₀ and D ₉₀ of the first particle and the mesh of the sieve used in the sieving of the second particle are also shown.

(Solid content)

The obtained pastes were collected into a 100 ml beaker, and mineral spirits were added and dispersed. Next, it is allowed to stand in a dryer to dry it, and thereafter it is cooled to room temperature in a dryer. Next, the mass of the residue in the beaker was measured, and the solid content (mass%) was calculated by the following formula (2).

Solid content (mass%)=(W2/W1)×100...(2)

(In formula (2), W1 represents the mass of the paste before drying, and W2 represents the mass of the residue after drying and cooling).

(D ₅₀ and D ₉₀ )

0.25 g of each paste was added to 10 ml of toluene to prepare each sample, and the particle size distribution of the sample was measured using a particle size distribution measuring device (Microtrac HRA 9320-X100, manufactured by Honeywell). D ₅₀ and D ₉₀ .

(Passing rate)

The passing rate of a sieve with a mesh of 150 μm was measured for each paste obtained by the wet sieve method. Specifically, 30 g of each paste was transferred to a 150 ml beaker, and 100 ml of mineral spirits was gradually added thereto to prepare a sample obtained by dispersing the paste. Next, a sieve with an opening of 150 μm is fixed to the recovery container (container 1), and the prepared sample is poured onto the mesh of the sieve. In addition, a small amount of mineral spirits is used to clean the sample remaining in the beaker, and the cleaning liquid is also poured into the screen of the screen.

Next, add mineral spirits to a recovery container (container 2) of the size that can accommodate the aforementioned screen, and fill the mineral spirits to about half the depth of the recovery container. Next, put the above-mentioned screen into the container 2 and immerse the net of the above-mentioned screen to the liquid surface of the mineral spirit, thereby immersing the sample remaining on the net into the mineral spirit in the container 2. In this state, the screen is vibrated to perform sieving. After that, the mineral spirits in the container 2 are replaced, and the above-mentioned sieving operation is performed again.

Repeat the above operations, and end the sieving at the stage when the sample falling from the sieve to the mineral spirit disappears, that is, when the flaky stainless steel particles passing through the sieve disappear. Furthermore, the presence or absence of flaky stainless steel particles passing through the mesh of the screen was confirmed by visual inspection.

Next, the sieve with the sample remaining on the net is placed in a dryer maintained at 105±2°C for drying, and then cooled. Finally, the dried flaky stainless steel particles on the net are recovered, and the pass rate (mass%) of the 150μm sieve of the flaky stainless steel particles in the paste is calculated according to the above formula (1).

Furthermore, the mass of the flaky stainless steel particles before sieving is the mass of the flaky stainless steel particles obtained as follows: 10g of the paste is placed in a dryer maintained at 105±2°C for drying, and thereafter Cool down.

Referring to Table 1, the solid content in the paste containing flaky stainless steel particles 1 to 3 (in Table 1, represented as particles 1, particle 2 and particle 3) are all 90% by mass, 150μm mesh sieve The pass rate of the net is 99.9%. In addition, the D ₅₀ and D _{90 of the} flaky stainless steel particles 1 to 3 are shown in Table 1, respectively.

<Production of formwork for concrete forming>

(Example 1)

Prepare a JIS-A1100-H24 300mm×300mm (thickness 1mm) board of 1000 series aluminum with a purity of 99.00% or more, and perform degreasing treatment on the surface of the board to prepare the substrate.

On one surface of the prepared substrate, a hexavalent chromate coating (thickness: 1 μm or less) as a compound coating is formed as a first intermediate layer.

Next, an intermediate coating was applied to the first intermediate layer as a second intermediate layer by a spray coating method, and dried at 120° C. for 20 minutes to form an intermediate coating film (thickness: 10 μm). In the intermediate coating, epoxy primer (manufactured by TOHPE Co., Ltd., product name: "metal under#600T") is used.

Next, a protective layer was formed on the second intermediate layer to complete the formwork for concrete forming of Example 1. The protective layer is formed in the following manner.

First, prepare a paint obtained by mixing the main agent and hardener containing the ingredients shown in Table 2 at a ratio of 4:1 by mass. Secondly, add solvent A in Table 2 to dilute the paint, straight Until the viscosity of the coating becomes the best viscosity for spray coating. Next, the diluted paint was applied by spray coating and dried at 80°C for 30 minutes. Thereby, the protective layer (thickness: 40 μm) was formed on the second intermediate layer.

Furthermore, the solvent A shown in Table 2 contains the components shown below.

Ethyl acetate: 30% by mass

Butyl acetate: 10% by mass

High boiling point solvent #100 (manufactured by Godo Solvent Co., Ltd.): 20% by mass

Xylene: 30% by mass

Ethylene glycol monoethyl ether acetate: 10% by mass.

In addition, the [solid content ratio] shown in Table 2 is the solid content ratio in each component. For example, it means that the flaky stainless steel particles 1 contained in the main agent are paste-like, and 90% by mass is the solid content ratio (the mass of the flaky stainless steel particles).

(Example 2)

In Example 2, a coating containing the ingredients shown in Table 3 was applied by spray coating, dried at 80°C for 30 minutes, and then fired at 190°C for 20 minutes to form a protective layer. Except for the above, in the same manner as in Example 1, a formwork for concrete forming was produced.

Solvent B shown in Table 3 contains the components shown below.

Butyl cellulose: 55% by mass

Methyl ethyl ketone: 45% by mass.

(Example 3)

In Example 3, a brush was used to coat the protective layer and then coated with a lubricant (manufactured by Sagami Co., Ltd., product name: "sanamold No-2") to form a surface layer, except that it was the same as Example 1. Ground production of templates for concrete forming.

(Example 4)

In Example 4, the flaky stainless steel particles 2 were used instead of the flaky stainless steel particles 1 to form the same surface layer as in Example 3, except that the formwork for concrete forming was produced in the same manner as in Example 1.

(Example 5)

In Example 5, the flaky stainless steel particles 3 were used instead of the flaky stainless steel particles 1 to form the same surface layer as in Example 3, except that the formwork for concrete forming was produced in the same manner as in Example 1.

(Comparative example 1)

In Comparative Example 1, the base material of Example 1 (wherein, degreasing treatment was performed) was used as a template for concrete forming.

(Comparative example 2)

In Comparative Example 2, acrylic resin paint (manufactured by TOHPE Co., Ltd., product name: "Toa GP Paint") was applied to form a protective layer (thickness: 30 μm) instead of the protective layer of Example 1. In addition, It was produced in the same manner as in Example 1.

(Comparative example 3)

In Comparative Example 3, a fluororesin coating (manufactured by TOHPE Co., Ltd., product name: "NEW GAMET#2000") was applied to form a protective layer (thickness: 30 μm) instead of the protective layer of Example 1. In addition, It was produced in the same manner as in Example 1.

<Evaluation of Hardness>

The hardness of the surface on the side where the protective layer was formed of the concrete forming formwork of Examples 1 to 5 and Comparative Examples 1 to 3 was measured. The hardness measurement is based on JIS K5600-5-4. The results are shown in Table 4.

<Evaluation of peelability from concrete forming bodies>

The concrete forming formwork of Examples 1 to 5 and Comparative Examples 1 to 3 was set as the bottom surface, and a wooden formwork with internal dimensions of 12cm in length×20cm in width×25cm in height was placed on the form for concrete forming to make the A formwork structure for concrete forming for the inflow of ready-mixed concrete.

The ready-mixed concrete is poured into the formwork structure for concrete forming to a height of 20 cm. After that, after vibrating the poured ready-mixed concrete with a vibrator, it is left for 5 days to solidify the ready-mixed concrete.

After that, the formwork structure for concrete forming was disassembled to peel off the formwork for concrete forming from the concrete forming body, and the surface state of the formwork for concrete forming after peeling off and the surface state of the concrete forming body were visually observed. Furthermore, when the surface of the concrete forming formwork is smooth during visual inspection, the concrete forming formwork is used repeatedly to produce the concrete forming body. The results are shown in Table 4.

In Table 4, the "protective layer" column indicates the type of flaky stainless steel particles contained in the protective layer and the type of resin. The column of "Hardness" shows the result of the hardness measured by the above method. Furthermore, among 4H and 2H, 4H has a higher hardness.

As shown in Table 4, the protective layer of the concrete forming formwork of Examples 1 to 5 has a hardness of 4H. Furthermore, it can be understood that the hardness measured on the surface side of the formwork for concrete forming in Examples 1 to 5 is the hardness of the protective layer according to the following circumstances: Even though Examples 3 to 5 have a surface layer, they are similar to those of Examples 1 and 5 2 The same hardness (4H), and the hardness of Comparative Examples 2 and 3 with a protective layer that does not contain flaky stainless steel particles is 2H.

In addition, in Examples 1 to 5, when the same concrete forming formwork was repeatedly used 10 times, the peelability between the concrete forming body and the concrete forming formwork was also good, and there was no such thing as attaching concrete to the surface of the concrete forming formwork. In the case of a part of the forming body, the concrete forming body and the formwork for concrete forming have smooth surface conditions. It is presumed that the reason lies in the hardness of the protective layer formed on the surface of the concrete forming formwork of Examples 1 to 5 It is higher and has higher corrosion resistance, so the damage of the protective layer caused by vibration etc. is suppressed.

In addition, it can be seen that the protective layers of Examples 1 to 4 have higher hardness than that of Example 5. The reason for this presumably is that, in Examples 1 to 4 used in the sheet-shaped stainless steel particles of 1 and 2 is greater than D ₅₀ D flaky particles of Example 5 the stainless steel used in ₅₀ of the third embodiment.

On the other hand, in Comparative Example 1, since the first use, the surface of the formwork for concrete forming has been corroded. In addition, it is also difficult to separate the formwork for concrete forming from the concrete forming body, and the surface of the obtained concrete forming body is not in a smooth state. It is presumed that the reason is that the surface of the base material is corroded due to the reaction of the alkali component in the concrete with aluminum, so the surface condition of the obtained concrete is not smooth due to its influence. Furthermore, it is also speculated that the concrete and the base material are strongly bonded together with this, so peeling becomes difficult, and the surface state of the concrete formed body after peeling does not become smooth.

Moreover, in Comparative Example 2 and Comparative Example 3, the first demoldability was good, and the surface of the obtained concrete formed body was in a smooth state. However, in the stage of repeated use for 5 times, the surface of the concrete forming form was corroded, and the surface of the concrete formed body obtained at this time was not in a smooth state. It is presumed that the reason is caused by the following results: in the stage where the number of repeated uses is small, the protective layer containing resin can function, but as the number of repeated uses increases, the protective layer is damaged or slightly damaged due to vibration, etc. Cracks, etc., so that the alkali component penetrates from these parts, and the corrosion of the substrate gradually occurs.

The embodiments and examples of the present invention have been described as described above, but it is also planned to appropriately combine the configurations of the above-mentioned embodiments and examples at first.

It should be considered that the embodiments and examples disclosed this time are illustrative in all aspects and not restrictive. The scope of the present invention is indicated by the scope of the patent application rather than the above description, and is intended to include the meaning equivalent to the scope of the patent application and all changes within the scope.

1‧‧‧Substrate

1a‧‧‧surface

1b‧‧‧surface

2‧‧‧Protection layer

3‧‧‧The first middle layer

4‧‧‧Second middle layer

10‧‧‧Formwork for concrete forming

II‧‧‧Region

Claims (7)

A formwork for concrete forming, comprising: a base material; and a protective layer provided on at least a part of the surface of the base material; and the protective layer includes flaky stainless steel particles; a mesh of 150 μm mesh of the flaky stainless steel particles The pass rate is over 99.0% by mass. The formwork for concrete forming according to claim 1, wherein the base material includes at least any one of aluminum or aluminum alloy. The formwork for concrete forming according to claim 1 or 2, wherein the protective layer contains 5 mass% or more and 58 mass% or less of the flaky stainless steel particles. A concrete forming body formed by the formwork for concrete forming according to claim 1. A concrete structure provided with the concrete formed body according to claim 4. A method for manufacturing a concrete forming body, comprising the steps of: arranging one or more concrete forming templates as in claim 1 into a desired positional relationship, and filling the above-mentioned concrete forming templates with ready-mixed concrete Step; and the step of separating the concrete forming body formed by curing the ready-mixed concrete from the above-mentioned concrete forming formwork. A method of manufacturing a concrete structure, comprising the steps of: using a concrete formed body manufactured by the manufacturing method of claim 6 to manufacture a concrete structure.

Images